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For our worldwide customers, we develop and implement solutions for the production and testing of rotors, stators and e-machines. As a system integrator, we take care of all aspects from material handling and complex manufacturing processes to the finished, tested product. We focus on the highest quality standards and efficient production.
As a specialist in eDrive solutions, we are your partner for the production of stators with various winding technologies such as Hair-pin, I-pin and X-pin. With cycle times of 60-600 seconds, we achieve high output rates with maximum reliability for highest productivity. In addition to low cycle times, we offer semi-automated setup for different product types in terms of length, diameter and geometry for even more flexibility. From semi-automated to fully automated, we enable individual system concepts with different conveyor technologies and intelligent robot solutions. We complement our proven standard process stations with innovative AI-based solutions for even greater efficiency. We also support you throughout the entire process, from product development and prototyping to series production.
Our scalable solutions enable efficient and cost-effective separation of stator-related wires (connection, special and joint wires). For high-precision handling of the wires, especially in the case of quality differences between batches, we use NC axis handling for maximum process stability. Alternatively, for less complex stators, we will in future offer the more cost-effective wedge or ring separation, which can reduce the cycle time by up to 50% and the programming effort significantly.
Our twisting solutions include synchronized twisting from 2 to 10 tracks. We set the wires upwards, which protects the tool and reduces the risk of wear from falling material particles. Our process is very robust and enables 360° rotation, allowing us to twist almost any type of product. This makes us a flexible partner for various applications.
When the wires are clamped, the wire ends are aligned block by block in the welding position to create the zero gap. With us, clamping does not take place in the laser station, but in a tool-bound external station. This allows external maintenance of the clamping tool, reduces the complexity of the laser system, and increases machine availability and uptime.
Our solutions provide customizable, user-friendly, flexible and reliable laser welding technology for wire ends and busbars. We integrate optimal system technology from various manufacturers, including high-power lasers up to 10 kW (higher powers are possible) and single-mode fiber lasers up to 4 kW. The positioning accuracy of the welding is +/- 100 µm. We offer active laser protection and a cycle time (depending on the product) of > 60 seconds with ~ 140 welding points.
With 30 years of experience in vision system integration, we are a reliable partner for high-quality optical inspection machines and solutions for all types of eDrive stator welds and other parts. Our camera systems are highly innovative and provide 360-degree image capture for 3D visualization, giving the viewer an all-around view of the weld. This makes it much easier to assess the quality of the welding process. Our fast and reliable detection of good and bad parts increases efficiency and reliability.
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We offer a wide range of robotic and transfer solutions to meet the individual cycle time and handling requirements of our customers. These customized system concepts are validated and optimized at an early stage using digital material flow simulation in order to guarantee the planned manufacturing strategy and production processes.
Andreas Ruta | eDrive